NEW MACHINERY FOR EMI's WOODSHOP WILL INCREASE EFFICIENCY

To boost production and meet the increased demand from our customers, EMI Industries took advantage of the Atlanta IWF show pricing and purchased new machines to replace the existing Holzma panel saw and Weeke machining center.  Installation of these new machines has begun.

Both machines employ Beckhoff computer technology to drastically reduce the cycle times and make them far more productive than their predecessors.  Using fiber optic technology, information travels from the operations computer to the moving parts of the machines at a much faster pace than ever before.

The Holzma Hpp-380 front load panel saw has several other features that were not available on the former HPP-81 saw. The most revolutionary and beneficial is Holzma's patented "shark fin" side pressure device.  The "shark fin" is a simple design with far fewer working parts, is much faster, much more durable and versatile than the old roller style side pressure device.  The "SPD" will square any size board and any thickness of material without issue.

The new Holzma also features a rugged "rack and pinion" saw carriage drive that allows this speedy machine's saw carriage to start and stop on a dime.  This feature not only helps with faster cycle times, it is also a great safety benefit.

As a complement to the new saw, EMI also purchased a "Holzma Optilift" that will replace the existing scissors lift that feeds the panel saw. Labor costs are reduced as it allows multi-stack cutting without a lot of physical effort to load the saw.

The new Weeke Venture 3 CNC machining center is packed full of features that increase operation speeds, improve quality and help "dummy proof" machine operation. Three main features are key to its efficiency.

First, a patented "LED" pod placement system, which lights along the consoles and the front of the machine to help the operator quickly align the suction pods into proper position, prevents damage. 

The second key feature is an integrated C-axis that allows the use of adapter aggregates to drill or rout horizontally at any angle.  A special "floating head" aggregate has been purchased to allow "constant depth processing" in materials that vary in thickness.

The final key feature of the new Weeke is the utilization of dual Z-axis technology. Essentially Weeke took the routing and drilling units and put them on separate guide-ways to allow them to go up and down separately.  This allows for faster changeover times from drilling to routing.  It also allows the processing head to be smaller, weigh less and thus put less strain on the guide-ways and create less long term maintenance.

These new machines purchased from Stiles Machinery are the two single fastest machines of their kind on the market today. They also have the same rugged durability as their predecessors and should serve to keep EMI Industries in its technologic leadership position for years to come for many years to come.

Thanks to attending an informative Webinar hosted by A.R.E. (Association for Retail Environments), of which EMI Industries is a current member, EMI management staff acquired additional information on the hottest topic for wood product manufacturers.  C.A.R.B. (California Air Resources Board) will begin regulating the quantity of formaldehyde, a toxic air contaminant, emitted from composite wood sold, or used to make finished products in the state of California.  The new regulation will be phased in starting January 1, 2009.  As this only stands for wood shipping into California, not all manufacturers are required to adhere to these new regulations just yet.   

Continually at the forefront of the industry, EMI Industries is taking the initiative to comply with C.A.R.B.'s regulations, for all of the wood products it manufactures not just those shipping into California. The materials used by EMI Industries used to make finished products which will be compliant by January 1, 2009 include melamine, particle board and laminate.  Additionally, C.A.R.B. compliant products will be tagged accordingly prior to leaving EMI facilities.  This ensures that manufactured wood products emit no additional formaldehyde into the air. 

The primary benefits of the new regulations are the reduction in formaldehyde emissions, total public exposure, and excess cancer risk in California.  EMI Industries is pleased to contribute to the overall well being of workers and the environment. 

A cool thing happened last week.  A representative from the Rachael Ray television show - Yes! Rachael Ray, the daytime cooking show with spunk - contacted EMI Industries to inquire about our checkstand products. 

The show is planning on airing an episode featuring the National Grocery Bagging contest. Recognizing EMI Industries and a leading checkstand manufacturer, they looked to us for the 6 identical grocery collection and bagging end units required for the competition. Of course you can imagine we were excited and open to this unique opportunity.   Unfortunately, the timing of the call, coupled with the fact we are having our best two months (back-to-back) ever in sales and revenues had all of our plants filled to capacity. The Rachael Ray show needed the baggers in 3 days. That just wasn't feasible as customers were counting on us. We had to decline.  Nevertheless, Rachael Ray will keep us in mind for upcoming opportunities.  So, thanks for thinking of us Rachael Ray!

When making items such as millwork products that are used in commercial applications, all elements need to be their absolute best and construction must be perfect in order for them to handle heavy traffic and abuse. An important element of millwork products is how the edges are finished. EMI Industries is confident the construction techniques and materials we have developed over the last thirty years are the absolute best available. To create an indestructible edge we use 3mm PVC (polyvinyl chloride) edge banding that is both chemically resistant and comes in infinite colors and patterns. Below are a few pointers to explain why this amazing material is worth the extra cost:

• Very Impact Resistant - 3millimeter edge banding cushions the blow. Objects deflect off of it allowing the laminate panels to stay chip free and new in appearance.

• Will not peel off - 3mm edge banding is applied with a dedicated edge bander using VERY hot adhesive, that is heated to 190 degrees Fahrenheit. The result is a very strong bond.

• The colors one can get for 3mm edge banding are limitless. Since the pattern or color is done photographically, the customer can get any color matched exactly to their product.

• Cost effective in the long run- While 3mm edge banding is more expensive than the more commonly used .018 PVC edge banding, its durability surpasses the thinner material by leaps and bounds. The combination of the impact resistance of the 3mm material and the impenetrable glue bond to the wood panel virtually eliminates the chance for chipping or damage to the edges. The life of the cabinet or fixture is thereby extended for years.

In our marketplace, I have noticed that there seems to be a general lack of knowledge in care and cleaning of stainless.  I did some research to get more information on the topic.  Below is an article that I have expanded on, from Packer Engineering, in Naperville, IL.

Contrary to popular belief, stainless steels ARE susceptible to rusting.

Corrosion on metals is everywhere.  It is recognized quickly on iron and steel as unsightly yellow/orange rust.  Such metals are called "active" because they actively corrode in a natural environment when their atoms combine with oxygen to form rust.

Stainless steels are passive metals because they contain other metals, like chromium, nickel and manganese that stabilize the atoms. 400 series stainless steels are called ferritic, contain chromium, and are magnetic; 300 series stainless steels are called austenitic contain chromium and nickel; and 200 series stainless, also austenitic, contains manganese, nitrogen and carbon. Austenitic types of stainless are not magnetic, and generally provide greater resistance to corrosion than ferritic types.

With 12-30 percent chromium, an invisible passive film covers the steel's surface acting as a shield against corrosion. As long as the film is intact and not broken or contaminated, the metal is passive and stain-less.  If the passive film of stainless steel has been broken, equipment starts to corrode.  At its end, it rusts.

Enemies of Stainless Steel

There are three basic things which can break down stainless steel's passivity layer and allow corrosion to occur.

1. Mechanical abrasion
2. Deposits and water
3. Chlorides

Mechanical abrasion means those things that will scratch a steel surface.  Steel pads, wire brushes and scrapers are prime examples.

Water comes out of the faucet in varying degrees of hardness.  Depending on what part of the country you live in, you may have hard or soft water.  Hard water may leave spots, and when heated leave deposits behind that if left to sit, will break down the passive layer and rust stainless steel. Other deposits from food preparation and service must be properly removed.

Chlorides are found nearly everywhere.  They are in water, food and table salt.  One of the worst chloride perpetrators can come from household and industrial cleaners. 

So what does all this mean?

Here are a few steps that can help prevent stainless steel rust.

1. Use the proper tools.When cleaning stainless steel products, use non-abrasive tools. Soft cloths and plastic scouring pads will not harm steel's passive layer.  Stainless steel pads also can be used but the scrubbing motion must be in the direction of the manufacturers' polishing marks. 
2. Clean with the polish lines.  Some stainless steel comes with visible polishing lines or "grain." When visible lines are present, always scrub in a motion parallel to the lines.  When the grain cannot be seen, play it safe and use a soft cloth or plastic scouring pad.
3. Use alkaline, alkaline chlorinated or non-chloride containing cleaners.  While many traditional cleaners are loaded with chlorides, the industry is providing an ever-increasing choice of non-chloride cleaners. If you are not sure of chloride content in the cleaner used, contact your cleaner supplier.  If your present cleaner contains chlorides, ask your supplier if they have an alternative.  We recommend a commercially available cleaner, Steel Shine. Avoid cleaners containing quaternary salts; it also can attack stainless steel and cause pitting and rusting.
4. Treat your water.  Though this is not always practical, softening hard water can do much to reduce deposits.  There are certain filters that can be installed to remove distasteful and corrosive elements.  To insure proper water treatment, call a treatment specialist. 
5. Keep your food equipment clean. Use alkaline, alkaline chlorinated or non-chloride cleaners at recommended strength.  Clean frequently to avoid build-up of hard, stubborn stains.  If you boil water in stainless steel equipment, remember the single most likely cause of damage is chlorides in the water.  Heating cleaners that contain chlorides have a similar effect.
6. Rinse, rinse, rinse.  If chlorinated cleaners are used, rinse and wipe equipment and supplies dry immediately. The sooner you wipe off standing water, especially when it contains cleaning agents, the better.  After wiping equipment down, allow it to air dry; oxygen helps maintain the stainless steel's passivity film.
7. Never use hydrochloric acid (muriatic acid) on stainless steel.
8. Regularly restore/passivate stainless steel.
9. Recommended cleaners for specific situations

Review

1. Stainless steels rust when passivity (film-shield) breaks down as a result of scrapes, scratches, deposits and chlorides.
2. Stainless steel rust starts with pits and cracks.
3. Use the proper tools.  Do not use steel pads, wire brushes or scrapers to clean stainless steel. 
4. Use non-chlorinated cleaners at recommended concentrations.  Use only chloride- free cleaners.
5. Soften your water.  Use filters and softeners whenever possible.
6. Wipe off cleaning agent(s) and standing water as soon as possible.  Prolonged contact causes eventual problems.

1.) NSF requires a minimum of a 1/8th inch radius on all vertical corners for ease of cleaning. The competitors sink did not use sufficient weld material to allow the corner to be ground to meet this measure.

OTHER                                                     OURS

All four corners need to have filler wire added to the vertical weld so that the weld radius measures a minimum of 1/8". We use filler wire to build this area up, then a rotating file to shape the radius.

2.) When welding the bowls into the sink/drain board deck, the juncture must be polished. Correct and careful polishing of welds makes the difference between a sink that is just functional and one that imparts a first quality image. This is a time consuming but a very important step.

OTHER                                                     OURS
The drain boards and back splash of the left sink looks scratched instead of polished.  Regraining the entire adjacent surface with a course grinding tool is a quick, but less visually satisfying means for blending in welded seams.  Careful polishing only the junction area with progressively finer tools allows the natural beauty of the stainless to flow uninterrupted as in the photo on the right.

3.) Even though the back of the splash will likely never be seen once the sink is installed and caulked to the wall, we take the time to be sure there are no sharp exposed weld slag and we spray the area to add an additional protective coating.

OTHER                                                     OURS

4.) These multi-bowl sinks have a full front ‘skirt' panel covering the bowls. NSF requires this or strips of stainless top to bottom at the juncture points of the sink bowls. A full skirt such as this is more expensive but provides the user with a singe smooth solid surface that can be easily cleaned. In this instance the competitor neglected to seal the top of the skirt with an NSF (or any) caulk. This would not have passed an NSF inspection.

OTHER                                                         OURS
The seam where the top edge of the skirt meets the bottom of the deck needs to be caulked with silver, NSF approved sealant as shown in the photo of our sink. We caulk the entire seam with silver, NSF approved sealant.

5.) Like the front, the seams between the bowls on the back and bottom must also be sealed. Caulk filler is sufficient here. Again, the other sink with no caulking in either place and would not have passed NSF.

OTHER                                                          OURS
The seam where the bowls meet at the rear of the sink needs to be caulked. We caulk the entire seam with silver, NSF approved sealant.

There are many standard sinks available to foodservice dealers that have details dictated by cost rather than what will serve the customer over the long haul and make it easy to clean. We make and sell quality, which is the best value.

I was doing some research the other day on stainless steel and came across a stainless steel soap bar!

Apparently, they are available in several different shapes. The one's I've see resembles a bar of Lifebuoy, or a teardrop. Each of these is really nothing more than a hollow hunk of stainless steel. Apparently, stainless steel is a neutralizer, so if you have been filleting a fish or cooking with garlic, you can rub your hands under water with stainless steel and VOILA, the putrid smell of whatever was on you hands, disappears! Stainless steel will actually free our skin of offensive odors when rubbed.

You may ask why stainless steel is ‘green' and what does this have to do with EMI Industries? Well, all of our stainless steel is 100% recyclable and what we purchase has at least 80% recycled content. We recycle all scrap stainless we produce in our production processes and carefully segregate each alloy into separate bins. What could be greener than a deodorant that never wears out and never needs to be replenished? If you should ever want to dispose of it, it is 100% recyclable!

The kicker is you DON'T have to buy it in soap form!! If your working with raw fish, just wash your hands as you would normally do and then, if you are washing in a stainless steel sink (like those from EMI Industries), rub your hands over the sink bowl and presto, the odor is gone. I'm sure there is a scientific explanation for why this works but the important fact is, it does!

EMI Industries is a custom manufacturer of fixtures and displays.  One of our product lines that have a lot of elements to them are checkstands.  I’ve asked around and got some ideas on what EMI Industries looks into when custom designing a new checkstand for a customer!

• Streamlined: Supermarkets and mass merchandisers have to consider their customers first and foremost. They want their customers experience to be positive so the shape and edges of the check out counters take on great importance. Thinking about how a customer can best move through the cash wrap line smoothly is critical to the overall shopping experience.
• Ergonomic Checkstands: While the main focus is often on the customer, a comfortable and efficient work environment will pay big dividends in worker moral and longevity of employment. Designing checkstands with point of sale systems at the correct height, bagging racks angled for easy access, padding at common touch points, and properly positioned foot rests are only some ways of reducing physical strain on your employees.  Check out Ergonomic Checkstands for more information.
• Counter Height: Consider the wide range of heights of your customers when it comes to them paying for items.  If a customer has special needs and is in a wheelchair, how can you accommodate them?  EMI Industries designs checkstands that considers all people who are using their products.
• Bagging and Catch Area: A long wait when checking out is the single biggest complaint of shoppers. One critical area that affects the smooth flow of a checkout line is the collection area for bagging. To be properly sized, analysis must be made of such factors as; the number of people that go through the line per hour at various times of the day; size of shopping carts being used; the largest volume of product any one shopper may have and the percentage of large volume shoppers to average shoppers; how many people write checks, use credit cards, or pay with cash; and, ‘paper or plastic?’ Is there one bagging rack? Two? Does the checker need to have a bagging rack? If a catch area is too small or too large it can hold up the line. Properly sized and shaped for maximum efficiency, your customer’s last impression of your store will be positive.
• Colors and esthetics:  While grocery shopping to some is a chore, it is a necessity to everyone. Checkout counter’s location at the front of the store makes them the first thing a customer sees when they come in and the last fixture they see when leaving. Is appearance important? Once the ergonomics and functionality have been determined and designed into the checkout, all which is left is to get the look that is right for the store. Warehouse and discount club stores may want a clean, simple efficient look; a natural food store might benefit from soft natural colors and the use of sustainable materials; and an upscale market may be best served with a curvaceous counter made from solid surface and stainless. When it comes to colors, laminate and solid surface material suppliers offer just about anything one could desire.

For functionality and appearance, no store fixture has greater importance to the success of a business than the checkout counter. Only one that has been custom designed to the unique set of requirements of the customer can help to maximize that stores business opportunity.

Here are some factors to think about when researching an ergonomic checkstand:

Cashiering

* Are items within easy reach?
* Are keyboard supports adjustable?
* Can the cashier work with items at about elbow height?
* Can the display be read without twisting?
* Are all edges smoothed or rounded so the cashier does not come into contact with sharp or hard edges?
* Are objects easily scanned the first time?
* Are objects scanned without twisting hand motions?
* Can cashiers scan heavy/bulky/awkward items without lifting them?
* Are the scale, conveyor, and horizontal scanner plates all the same height?
* Is the scanner plate clean and unscratched?
* Does the cashier have an anti-fatigue mat and/or footrest?
* Are there Lean Bars available?
* Is there Lean Pad available?
* Do the checkstands come in right and left hand versions?
* Will Scan Guns be available for easy scanning access?

Bagging and Carry Out

* Can the bagger adjust the height of the bag stand?
* Are all edges smoothed or rounded so the bagger does not come into contact with sharp or hard edges?
* Do bags have handles?
* Can the bagger put bags into cart without leaning over the checkstand or twisting the back?

With these pointers you should be well informed and able to address all issues when finding the best equipment for assisting your employees, to be safe and successful.

For additional information:

http://www.emiindustries.com/products/checkstands

http://www.osha.gov/Publications/osha3192.pdf

Not sure if you knew this but EMI Industries uses a fabulous program that not only is a powerful engineering tool, but also a high end graphics program that lets our customer’s see their product in a virtual sense, before it’s even constructed in the factory. 

SolidWorks is a 3D mechanical computer-aided design program, which EMI Industries uses to design our carts, checkstands, sinks, or whatever your needs are.  What is unique about EMI Industries is that we have manufacturing capabilities in two different processes, this being wood and sheet metal.  Not too many companies can claim this. 

Why is it the Coolest Software?

• SolidWorks automates a lot of functions that were previously done manually by the engineering department

• Models created in SolidWorks are as close as you can get to a physical part in a digital environment.

• Because it’s 3 dimensional, every inch of a model, inside and out can be view by the engineer and the customer, since it’s the closest thing to reality one has.

• SolidWorks ensures that parts fit the first time with no guess work

• 3D functionality helps on the production floor by giving assemblers more accurate views of the parts and assemblies they deal with

• The data from SolidWorks can be converted into E-drawings, an email software tool that allows the customer see their product before its manufactured and also make changes, if needed. There is no technical experience or special software needed to use E-drawings, therefore saving time and money.

If you have any questions, please fill out our Contact Form.  Also, this is the LAST day to fill out the form to be entered in to our “Win a Gift Certificate from Amazon.com!”